Resume - B. Tech in Metallurgical Engg, 27 years experience in Corrosion & Inspection fun...

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EXPERIENCE SUMMARY:

27 years of Corrosion Monitoring & Control / Inspection / Quality Assurance / Welding / function in various capacities which includes

- working in 4 operating refineries of Indian Oil Corporation Ltd. In India,
- 1 year working in a KNPC refinery, Kuwait, 2 months in Gas Plant, UAE
- Construction / project experience / commissioning of 2 new oil refineries.
- 14 years of Management Experience as Head of Inspection Department

PROFESSIONAL MEMBERSHIPS:
a) Indian Institute of Welding - Membership no. - DEI / M / R-8513
b) NACE International - Membership no. - 147815-00

CAREER PROFILE:
First and continuing employment in Indian Oil Corporation Ltd., India since 1977, in various grades of organization as below-

DESIGNATION From To

Dy. General manager April, 2004 continuing
Chief Insp. Manager May, 1997 March 2004
Senior Insp. Manager June,1993 June,1996
June, 1993 May, 1994
(Mina Abdullah Refinery, KNPC, Kuwait)
Inspection Manager May, 1989 May, 1993
Dy. Insp. Manager May, 1986 April,1989
Senior Insp. Engineer June, 1982 April, 1986
Inspection Engineer July, 1978 May, 1982
Engineer Trainee July, 1977 June, 1978

DETAILS OF EXPERIENCE:

1. Corrosion monitoring and control in following areas -

- Refinery process units like Crude and Vacuum distillation, Delayed Coker, FCC, Hydrogen Generation, Hydrocracker, Visbreaker, Catalytic Refining, Sulfur Recovery, amine treating, lube unit, solvent extraction, etc.,

- Thermal power station boilers, DM Plant and connected facilities.

- Cooling towers, cooling water system, Fire Water network, effluent treatment plant,

- Storage tanks for storage of petroleum, water and chemicals like acid, caustic - (floating as well as fixed roof type), Horton spheres, flare system and offsite piping - insulated as well as bare,

- Underground piping & storage vessels, cathodically protected piping, coat / wrapped, concrete coated piping.

The responsibilities included selection of materials, selection of paints, coatings & linings, corrosion prevention recommendations, failure investigation & analysis including metallographic studies, performance improvement and remaining life studies.

Examples of salient corrosion related activities are given at the end of this CV.

2. On stream / in-service and shutdown inspection of refinery process units and storage facilities, having equipments like reactors, columns, vessels, exchangers, heaters, boilers, piping, safety valves, storage tanks etc., Recommendations for repair / replacements and performance improvement.

Major plants / areas inspected - AVU, Hydrocracker, Hydrogen, Delayed coking, FCC, CRU, Visbreaker, Lube plant, Amine regeneration, Sour water stripping, sulfur recovery, boilers, storage tanks, underground piping, Cooling water system, effluent treatment, fire water system, etc.

The equipments inspected include those operating at temperatures upto 980C (reformer furnace) and pressure upto 160 kg/cm2 (Hydrocracker unit), metallurgy from carbon steel to alloy steels, stainless steels of various types, monel, inconel, incolloy, etc.

3. Quality Assurance of welding / fabrication jobs, stress relieving, NDT, repairs, interpretation of radiographs as per agreed national / international standards. The important activities include

- Selection of proper welding electrode / filler rod and welding process.

- Welder qualification

- Repair procedures developed for strip lining in old used columns,

- Repair of used hydrogen lines, welding of high thickness vessels

- Welding of crack prone parts, weld deposition in corroded areas of equipments / vessels, welding of cladded piping and equipments

- Welding of alloy steels, stainless steels, duplex stainless steels, high nickel alloys and dissimilar welding

- Welding / weld repairs in boilers, storage tanks, piping, columns / vessels, pump casings in hydrocarbons & chemical services.

4. Establishing and maintaining ISO-9001-2000 ( Quality Management System ), ISO-14001 ( Environment Management System ),& ISO-18001 (Safety Management System) in Inspection & Corrosion function, updation and coordination for periodic audits.

5. Experience of Project Jobs like construction / commissioning of new process units, power station, storage tanks & piping. I was involved in Inspection / Quality Assurance activities during construction / commissioning experience of two grass root refineries - Mathura & Panipat refineries of Indian Oil Corporation Ltd. Extensive PMI activities were organized during the project stage and material mix was found.

6. Awareness of relevant codes / standards like API, ASTM, NACE, ASME, ANSI and Inspection Procedures & Practices.

7. Inspection Planning & Scheduling for on-stream / shutdowns / statutory inspection, forecasting of repair / replacements, coordination with legal authorities.

8. Documentation of Inspection data / history, Computerization of Inspection Deptt, Preparation of Inspection / Corrosion reports, manuals, procedures and guidelines for use in refinery, organizing and imparting training to fresh / experienced engineers.

9. Familiar with common NDT methods, tools and instruments, Contracting of NDT agencies, monitoring their performance and evaluation of reports.

10. Worked in 4 Indian refineries, 1 refinery of KNPC, Kuwait and a Gas plant in UAE.

11. Management Experience:

Managing of Inspection / Corrosion Control / Quality assurance functions as Head of Inspection Department since last 14 years (since 1989, in 3 refineries) for safe, reliable and economical plant operation. Established Inspection Dept with infrastructure, tools & Instruments, documentation system, etc. at Panipat Refinery.

CURRENT ASSIGNMENT:
Dy. General Manager with following departments under my control –

- Inspection
- Fire & Safety
- Safety & Environment Protection

CORROSION AWARD: 'Excellence in Corrosion Awareness' award for year 2001 by NACE International, India section

SPECIALIZED TRAINING, SEMINARS & CONFERENCES:

Training obtained in:
- Industrial Radiography by BARC
- Corrosion Control by National Productivity Council
- Cooling Water Corrosion
- Welding
- NDT, Ultrasonic Flaw Detection
- Refractories
- Selection of materials
- Six Sigma method of performance improvement

Participation in Seminars and Conferences like

- 14th World Conference on NDT, 1996, New Delhi
- 5th National Convention on Corrosion, 1999, New Delhi
- 7TH National Convention on Corrosion, 2001, Bangalore, India
- International Conference - Petrotech, 2001 & Petrotech 1999, at New Delhi

PRESENTATION OF TECHNICAL PAPERS & FACULTY SUPPORT

- Papers presented at Failure Analysis Workshop at IOC R&D Center, Faridabad, OISD Workshop and Activity Committee Meetings of Center for High Technology, Govt. of India.

- Internal Faculty on Corrosion and Inspection. Delivered lectures on Inspection and Corrosion in Refineries at Haldia and Guwahati and also at Head Office in New Delhi.

- Presentation of investigation and failure analysis reports in technical and management forums

MEMBER OF FAILURE INVESTIGATION COMMITTEES:
I have been either convener or member of nearly 20 committees on different occasions for failure investigation and recommendations. Some examples
- Failure of Viramgram - Koyali cross country pipeline (1983-84)
- Ballooning of roof of storage tank at Guwahati Refinery (1992)
- Failure of LPG bulk loading hose at Guwahati Refinery (1992)
- Explosion and fire at Hydrocracker Unit at Panipat Refinery (1999)
- Failure of safety valve bleeder nozzle in CDU, Panipat Refinery (1999)
- Damage of VDU column internals, Panipat Refinery (1999)
- Quality Assurance Audit member, Panipat Refinery (1999)
- Failure of Heat Exchanger Flange Joint causing Unit Shutdown(2003)

OTHER ACTIVITIES
- Involvement in implementation of Total Productive Maintenance (TPM) system in refinery,

- Involvement in implementation of safety systems in refinery and its assessment as per International Safety Rating System (ISRS)

- Audit of Inspection System effectiveness for other refineries as part of Maintenance Management Audit

- Quality Assurance Audit (post construction) of Panipat Refinery

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Brief Description

B. Tech in Metallurgical Engg, 27 years experience in Corrosion & Inspection function in refineries

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